W91CRB20R0009 Attachment J-1 CWB Performance Specification DRAFT.docx

MIL-PRF-32383/X DRAFT

NOTE: This draft, dated 12 May 2020 has been prepared by US Army Project Manager Close Combat Squad (PM CCS) and the Combat Capabilities Development Command (CCDC) Command, Control, Communications, Computers, Cyber, Intelligence, Surveillance and Reconnaissance (C5ISR). This version has not been approved and is subject to modification. DO NOT USE PRIOR TO APPROVAL.

INCH-POUND

MIL-PRF-32383/4X (CR)

12 May 2020 DRAFT SUBJECT TO CHANGE WITHOUT NOTICE

SUPERSEDING

MIL-PRF-32383/4

6 March 2013

PERFORMANCE SPECIFICATION SHEET

BATTERY, RECHARGEABLE, SEALED, LITHIUM-ION, BB-2525 and BB-3525

The requirements for acquiring the product herein shall consist of this specification sheet and MIL-PRF-32383

FIGURE 1 - M32383/4A-3 (BB-2525) Lithium Ion and M32383/4A-4 (BB-3525) Lithium Polymer Conformal Batteries (See Figure 12 for dimensions) Note: Depicted battery is representative of a potential solution but is not a requirement within this document.

Unless otherwise specified, paragraph numbers are in reference to MIL-PRF-32383. Note that the requirement and verification paragraphs included in this document that are in addition to or modified from MIL-PRF-32383 are highlighted in BOLD.

2. APPLICABLE DOCUMENTS.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks.

Add:

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-83133 Turbine Fuels, Aviation, Kerosene Types, NATO F-34 (JP-8), NATO F-35, and JP-8 + 100

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130 Department Of Defense Standard Practice: Identification Marking Of U.S. Military Property

MIL-STD-461 Requirements for the Control of Electromagnetic Interference Characteristics of Subsystems and Equipment

MIL-STD-882 Department of Defense Standard Practice System Safety

MIL-STD-1472 Department of Defense Design Criteria Standard Human Engineering

(Copies of these documents are available online at http://quicksearch.dla.mil/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2.2 Other Government documents, drawings, and publications.

Add:

ADS-37A-PRF Electromagnetic Environmental Effects (E3) Performance and Verification Requirements (Relevant pages of this document can be found in APPENDIX A herein)

NWPAN-WP-01112013 Nett Warrior Interconnect Architecture White Paper (Available from: Product Manager Ground Soldier Systems (PdM GSS) Attn: SFAE-SDR-CCS, 5966 12th Street, Building 1024, Ft. Belvoir, VA. 22060) – Approved Nett Warrior compatible connectors.

2.3 Non-Government publications.

Add:

IEC 61000-4-5 Electromagnetic compatibility (EMC) – Part 4-2: Testing and measurement techniques - Electrostatic discharge immunity test

IEC 61000-4-9 Electromagnetic compatibility (EMC) – Part 4-9: Testing and measurement techniques Pulse magnetic field immunity test

(Copies of this specification available online from International Electrotechnical Commission https://webstore.iec.ch )

ASTM G115-10 Standard Guide for Measuring and Reporting Friction Coefficients

(Copies of this specification are available online from ASTM International http://astm.org )

Smart Battery Data Specification Revision 1.1 paragraph 4.4.4 (Copies of this specification are available online from SBS Implementers Forum (SBS-IF) at: www.sbs-forum.org) UN 38.3 Tests Series Recommendations on the Transport Of Dangerous Goods Manual of Tests and Criteria – Sub-Section 38.3 Lithium metal and lithium ion batteries, United Nations New York and Geneva, ST/SG/AC.10/11

Copies of this specification are available from United Nations Economic Commission for Europe at http://www.unece.org/trans/areas-of-work/dangerous-goods/legal-instruments-and-recommendations/un-manual-of-tests-and-criteria/rev6-files.html and applicable amendments e.g. http://www.unece.org/trans/areas-of-work/dangerous-goods/legal-instruments-and-recommendations/un-manual-of-tests-and-criteria/amend-to-rev6.html.

3. REQUIREMENTS.

Add: Specification requirements and test methods: The following requirements and test methods of MIL-PRF-32383, identified therein as “when specified”, are applicable or not applicable as indicated below:

“When Specified” Requirements

Paragraph Test Method Paragraph Applicability

4.7.2.15 Yes

1/ As modified herein, both mated and unmated configurations.

3.2.1 Certifications.

Delete 3.2.1 from MIL-PRF-32383 and replace with the following:

3.2.1 Certifications: Certification of conformity shall be provided for the following requirements. The Government reserves the right to verify any or all certifications.

Note: 1/ includes UN 38.3 Test Series

3.

3.4.3 Dimensions and weight.

Add: Width shall be 7.60 +/- 0.06 inches.

Height shall be 8.65 +/- 0.05 inches.

Depth shall be no less than 0.50 inches and not greater than 0.70 inches.

Weight shall be no greater than 2.6 pounds.

All other dimensions shall be accordance with Figure 12.

3.4.4.1.1 Connector.

Delete 3.4.4.1.1. from MIL-PRF-32383 and replace with the following

3.4.4.1.1. Nett Warrior Connector.

Glenair connector Part Number 8070-1939-07ZNU6.7SY (printed circuit board tails or solder cup) or TE Connectivity Part Number: 2828420-2 (7 position). The primary (master) keyway shall be oriented downward, facing the flat terminal contacts.

The battery connector shall maintain a fully functional interface after 500 insertions and extractions. When tested as specified in 4.7.1.3, battery connector shall not tear, rip, be displaced, or separate from the battery case.

The connector shall provide a shell to shell shield impedance of not greater than 4 milliohms when mated with any of the mating connectors listed in NWPAN-WP-01112013.

The ground (Socket 2 V- Battery Ground) shall be terminated just within the battery pack to the shield shell and shall have no more than 4 milliohms impedance between ground socket 2 and the shield shell. Connect the battery in accordance with Figure 14, and Cable G. Measure the impedance of a mated connector at the end of the cable attached to the battery. Provide certification that the shield to ground socket 2 impedance is less than 15 milliohms.

Sockets 1, 2, and 3 shall be capable of carrying not less than 5 amps continuous each.

Connector shall be capable of mating with plugs having the 6-6 or 6-7 pin configuration. The connector shall be sealed to meet the requirements of section 3.6.6 (Immersion). The connector shall be sealed in a way such that insertion of a plug with a 6-7 pin configuration does not compromise the ability to meet Immersion and other requirements herein.

The connector shall be located on the left side of the battery at 7.89 inches from the bottom of the battery +/- 0.5 inches to allow for USB connector spacing. Refer to Figure 12

The pinout for the connector shall be as follows in “Nett Warrior Connector Pinout Description” with socket numbering depicted in FIGURE 2 Cerification is required

INFORMATION TABLE 1 - Nett Warrior Connector Pinout Description

1/ Charge + shall be input only 2/ Safety Signal IAW Smart Battery Data Specification Revision 1.1 paragraph 4.4.4 3/ Require internal termination of Ground to Shield Ground.

4/ Shall not be used for any electrical connectivity or for grounding

FIGURE 2 - Nett Warrior Connector Pinout Assignment

Add:

3.4.4.1.1.1 Nett Warrior Connector disconnect pull force.

The connector shall have a 12.0 +/- 4.0 pounds of force disconnect. Test per 4.7.1.3.1

3.4.4.1.2 Flat terminal.

Add: The charge terminals shall be as shown in FIGURE 3, Charge Terminal Pinout Assignment. Charge terminals shall be electrically protected against short circuit and shall not source battery current. All four contacts shall be recessed 0.020 +/- 0.005 inches. The contacts shall support charging at a minimum of 7.5 Amps. They shall be designed minimally to sustain a 20 Lbs. force each for 10 minutes without degradation to the battery contacts from a charge contact pin. Test per 4.6.1 and 4.7.1.4.

The battery shall be capable of being charged via both the Nett Warrior connector and the charge terminal contacts. The battery shall be capable of “wake up” charging via both the Nett Warrior connector and the charge terminal contacts. Wake up charge charging via the Nett Warrior connector shall be IAW the Smart Battery Specified behavior for the Safety Signal. Wake up charging via the charge terminal contacts shall be performed by accepting +5V between terminal 1 and 2 and responding to SMBus commands before charging voltage is provided.

INFORMATION TABLE 2 - Charge Terminal Descriptions

FIGURE 3 - Charge Terminal Pinout Assignment

3.4.4.1.5 USB power port connector(s).

The CWB shall provide at least one USB 3.0 Type-A connector. The USB Connector shall be located within the Connector region of Figure 12. The USB 3.0 Type-A connector shall have the following characteristics:

a. A minimum of 1.5 Amps at 5 VDC female port (receptacle) shall be available.

b. A tethered protective cover

c. Connection of the Nett Warrior connector and USB Type-A connector shall be accomplished by the user wearing cold weather gloves when tested IAW MIL-STD-1472.

d. One (1) USB BC1.2 Dedicated Charging Port (DCP) capable of supplying 1.5 A of current.

e. A charger adapter emulator circuit to accommodate proprietary charging protocols such as Apple, Samsung, or Qualcomm Quick Charge.

f. The USB power port connector(s) shall be located per Figure 12.

g. The USB power port connector(s) position and orientation (horizontal or vertical) shall not interfer with operations with the Nett Warrior connector when wearing approved tactical gloves.

h. Verify in accordance of section 4.7.2.17

3.4.5 Battery case.

Delete from MIL-PRF-32383 and replace with the following:

3.4.5 Battery case.

The battery case shall be capable of maintaining the specified dimensions during the life of the battery. The surface of the case shall have a smooth finish free from pitting, blow-holes, rough spots, or other deformations. The case shall be fabricated of material having sufficient strength to withstand the environmental and electrical tests specified herein. Material shall be nonflammable. The case material shall be classified in accordance with UL Standard 94, Test for Flammability of Plastic Materials for Parts in Devices and Appliances, except as otherwise noted herein. Acceptable ratings include V-0, 5VA, or 5VB. If the manufacturer elects to use material classified in accordance with UL Standard 94, certification is required. If it is not UL Standard 94 certified, test as specified in 4.7.1.7 and as approved by the Government for validation; test specimens shall self-extinguish within 5 seconds after removal from flame.

Add:

3.4.5.3 Battery case vent.

Pressure release device(s) shall be located on the CWB in accordance with Figure 12.

3.4.5.6 Surface friction.

Batteries shall slide easily in and out of their pouch. When tested as specified in 4.7.1.8 batteries shall have a coefficient of static friction of not greater than 0.40 against a Cordura® fabric containing meta-aramid, nylon and cotton in a blend ratio of 43/30/27 percent by weight.

Add:

3.4.5.7 Battery case edges.

The battery case edges, seams, and corners shall be smooth.

3.4.6 Marking.

Add:

All marking and labels shall be in accodance with MIL-STD-130

3.4.6.2 Warning marking.

Add:

Warning labels shall be not less than a 12 point font; other labels shall not be less than a 10 point font.

3.4.6.5 Instructions / notes.

Add:

The following charging instructions shall be marked on each battery:

CHARGE CONSTANT VOLTAGE AT 16.8V AT 5 AMPS MAX THROUGH NETT WARRIOR CONNECTOR.

BATTERY TEMPERATURE SHOULD BE BETWEEN -4°F (-20°C) AND 122°F (50°C) DURING CHARGE.

LOWER TEMPERATURE CHARGING [BELOW 32°F (0°C)] IS PERMITTED, BUT RUNTIMES WILL BE LOWER.

WARNING / STORAGE

DO NOT STORE ABOVE 160°F (71°C),

CRUSH, MUTILATE, REVERSE POLARITY,

DISASSEMBLE, OR DISPOSE OF IN FIRE.

(Note: if charge voltage is different than 16.8 VDC, appropriate voltage should be stated on battery charging instructions.)

3.4.6.6 Simplified battery label.

Add:

The simplified battery label location shall be located on the same surface as the charging instructions.

Add:

3.4.6.9 Nett Warrior connector marking.

The Nett Warrior Connector marking shall be as shown in FIGURE 4 and orientated as in Figure 12. The orientation shall have the master key way facing down towards the bottom of the battery pack.

FIGURE 4 - Nett Warrior Connector marking details

3.4.8 Battery condition for shipping.

Delete MIL-PRF-32383 3.4.8 in its entirety and replace with the following:

3.4.8. Battery condition for shipping.

Each battery shall be shipped with an instruction card that shall contain instructions for operation, charging, and maintenance of the battery to include long term storage/shipping requirements per (Safety Data Sheet, class of shipping, and shipping markings).

3.4.8.1 Dust cap or cover.

Replace “Each battery shall be furnished with a dust cap” to “Each battery shall be furnished with a dust cap for shipping/transportation only”

Battery voltage.

Add:

Battery shall operate within the range of 10.0 volts to 20.0 volts.

3.5.3 Capacity.

Add:

Minimum final voltage: 10 volts.

When subjected to the specific test listed below and discharged at the specified rate to minimal final voltage, the battery shall have the following minimum capacity:

Test Capacity Requirements

3.5.5 Motor inrush current.

The discharge profile shall be as follows. Verify values in accordance with 4.7.4.12.

INFORMATION TABLE 3 – Motor Inrush

(second:millisecond:microsecond)

3.5.8 State-of-charge Indicator (SOCI).

Delete 3.5.8 from MIL-PRF-32383 and replace with the following:

3.5.

3.5.8. Digital display characteristics.

When tested as specified in 4.7.2.14, the display shall have the following characteristics:

a. There shall be a single digital display located on the top central edge of the battery (see Figure 12) that will have the capability of displaying State of Charge (SOC) “### %”; State of Health (SOH) “### H”; Run-Time-To-Empty (RTTE) “hh;mm E”; Charge-Time-To-Full (CTTF) “hh:mm F”; and Battery Cycle Count (BCC) “#### CY”. The digital display actuator shall be recessed and shall be protected from inadvertent operation and placed on the right side of the display. If display is required to be moved off center, it may be located up to 1.25 inched from center closer to the Nett Warrior Connector as per Figure 12.

b. The load applied by the digital display circuitry on the battery shall be not greater than 50 micro-amperes in the non-operating mode.

c. The device shall be designed to compensate for usage temperature and discharge rate and shall monitor and adjust for changes in both during battery use.

d. The accuracy of the information displayed shall be +0%/-5% based upon actual initial battery capacity.

e. The digital display shall provide readings for SOC and SOH of 0 to 100% in 1% increments and RTTE and CTTF in hh:mm. The display shall not be less than ¼ inch in height. The display shall visually distinguish between SOC, SOH, RTTE, CTTF, and BCC. The output of the display shall be discernable from any direction (i.e. clearly distinguish between readings of 001 and 100, or 85 and 58, or 001 versus 881, etc. from 3 feet at 45° angle from a perpendicular of the face of the display with persons with 20/20 vision).

f. A single depression of the Tactile Push Button Switch (TPBS) will bring up the display within 2 seconds of depression. (Refer to INFORMATION TABLE 4 - Display Transition Process.) If a there is a second quick depression (within 5 seconds of the prior depression), the display shall in a circular sequence transition to the next item in the sequence. (Refer to Figure 5 - Display Circular Display Function Transition.)

g. Subsequent depressions if within 5 seconds of each other of the TPBS will cycle the display functions in a circular matter from the prior depression to the next function state in not less than 0.25 seconds. Example if the battery was last displaying SOC, it would transition with depressions within the 5 second window SOC SOH RTTE CTTF BCC SOC SOH RTTE CTTF BCC SOC and so on. The TPBS shall comply with the transition process requirements of INFORMATION TABLE 4 - Display Transition Process and

h. Figure 5 - Display Circular Display Function Transition.

INFORMATION TABLE 4 - Display Transition Process

Note: The Final Display Function state, post the last TPBS depression, shall be displayed and illuminated for not less than 3 seconds. Quick depressions of the TPBS, within 5 seconds of the last TPBS depression, shall sequence the Display function to the next state in not less than 0.25 seconds of the TPBS depression.

Figure 5 - Display Circular Display Function Transition

i. Display items will be displayed for not less than 3 seconds fully illuminated and not more than 5 seconds with illuminated display after the TPBS is depressed with the ability to be read clearly in both day and night. If there is minimal parasitic loss, the display can continue to be provided as a non-illuminated (e.g. like a Liquid Crystal Display – not visible at night – not illuminated) the non-illuminated readout may remain on after 5 seconds post last depression. If the TPBS is quickly depressed, it will advance the display to the next display mode illuminated for night and day readability.

j. If the display button is held for 6 or more seconds, the orientation of the display will switch and be illuminated for not less than 3 seconds and not more than 5 seconds. The display shall remain in the last mode that was selected, unless the TPBS is depressed a second time within 5 seconds of the prior 6 second hold down of the TPBS to move it to the next mode in the sequence.

k. The digital display shall flash 000 indicating the battery has an internal fault preventing it from providing output power through any connector. Display will continue indefinitely with 000 displayed until any internal fault is gone or the battery is depleted.

l. RTTE shall be a display of the SMBus AverageTimeToEmpty(), calculated based on power.

m. CTTF shall be a display of the SMBus AverageTimeToFull(), calculated based on power.

n. The display shall be compatible with Night Vision Imaging Systems. The output of the display at full intensity, measured in a direction normal to the display shall be 1.0 to 10.0 millicandelas.

o. The display shall be capable of providing the correct information in a temperature range of −30 ºC to 55ºC.

p. The Display shall be capable of surviving temperature extremes of −40ºC to 93ºC. Certification to the full intensity output and storage temperature range requirements is required.

q. The digital display shall normally be in the ‘off’ mode and shall require a push-button actuator to activate the display. The push-button shall be capable of operation by Soldiers wearing Mission Oriented Protective Posture (MOPP) IV and cold weather gloves. The push-button actuator shall comply with the following displacement and resistance requirements in INFORMATION TABLE 5 – Pushbutton Requirements:

INFORMATION TABLE 5 - Push Button Requirements

r. When viewed at full intensity (sunlight day readable and in a dark room representing night readable), the display shall only illuminate the display state. The time to the display’s full light intensity shall be not greater than two seconds. The display shall remain at full intensity for not less than 3 seconds and shall self-extinguish in not greater than 5 seconds of actuation when the actuator is held down. The display shall extinguish any time the actuator is released in not greater than 5 seconds. The display shall be compatible with Army night vision gear.

s. The display orientation (readable front side or rear side) shall be configurable based upon user preference. Holding the tactile push button switch down for greater than 6 seconds shall toggle the default orientation of the display one time till released.

3.5.9 SMBus.

Delete 3.5.9 from MIL-PRF-32383 and replace with the following:

3.5.9 SMBus.

Each battery shall be compliant with System Management Bus (SMBus) Specification Revision 1.1 and Smart Battery Data (SBData) Specification, version 1.1. Batteries shall be compatible with appropriate Level 2 and Level 3 chargers (see 6.3.9). When tested as specified in 4.7.2.14, Relative State of Charge value shall be accurate within +0/-5% of the actual state of charge for the battery under test throughout the discharge. Manufacturer and battery data shall be correctly programmed (see 4.7.2.15).

SMBus shall use 5V logic circuitry. Pull-up resistors will be provided by the charger. SMBus output from the connector should be sufficient to maintain signal integrity through the two (2) cables depicted as “C” and “D” in Figure 13, and supplied at time of contract award. SMBus circuitry shall respond to a SMBus query within 2 seconds.

Add:

3.5.11 Concurrent charge / discharge.

When tested as specified in 4.7.2.16, the battery shall be capable of being charged via pin 3 and simultaneously discharged via pin 1 of the Nett Warrior connector (3.4.4.1.1).

When tested as specified in 4.7.2.16, the battery shall be capable of being charged via the flat terminal contacts (see 3.4.4.1.2) and simultaneously discharged via pin 1 of the Nett Warrior connector (3.4.4.1.1).

3.6 Environmental Requirements.

Delete Table I and replace it with the following:

TABLE 1 - ENVIRONMENTAL REQUIREMENTS

3.6.5 Vibration.

Replace “When tested as specified in 4.7.3.7” with “When tested as specified in 4.7.3.7 and 4.7.3.7.1 and meet the requirements of 3.12.”

Add:

3.6.9 Impact.

Batteries shall be capable of being impacted without sustaining physical or electrical damage. When tested as specified in 4.7.3.11 batteries shall meet the impact test capacity requirements of 3.5.3 and the requirements of 3.12 (with the exception of defects in 106 of TABLE VIII).

Add:

3.6.10 Flexibility.

Batteries shall be capable of flexing with a 1 inch displacement in both directions on each axis without sustaining physical or electrical damage. When tested as specified in 4.7.3.12 batteries shall meet the flexibility test capacity requirements of 3.5.3 and the requirements of 3.12.

Add:

3.6.10.1 Over Flexibility Force Protection.

Batteries shall allow support of not less than 45 Lbs. bending force for intervals of a minimum of 5 seconds each without failure or damage to the battery and verified in accordance with 4.7.1.1. The battery shall be tested as specified in 4.7.3.12.1 batteries shall meet the flexibility test capacity requirements of 3.5.3 and shall meet the requirements of 3.12.

Add:

3.6.11 Solar radiation.

Batteries shall be capable of withstanding prolonged exposure to sunlight without sustaining physical or electrical damage. When tested as specified in 4.7.3.13 batteries shall meet the requirements of 3.5.3 and the requirements of 3.6.

Add:

3.6.12 Salt fog.

Batteries shall withstand a salt fog atmosphere. When tested as specified in 4.7.3.14 batteries for unconnected, un plugged - unprotected power connector shall meet the salt fog test capacity requirements of 3.5.3 and the requirements of 3.12.

Add:

3.6.13 Electrostatic discharge (ESD).

Batteries shall withstand ESD to ±8kV, contact discharge and ±15kV air discharge on any surface, panel component (including vent), charge contacts, or power / data connectors, including exposed pins, in both operating and non-operating mode. When tested as specified in 4.7.3.15 batteries shall meet the ESD capacity requirements of 3.5.3 and the requirements of 3.12.

Add:

3.6.14 Conformability.

Batteries as they would be received post production, shall be capable of bending under not greater than 35 pounds of force around curved surfaces of a 7 inch radius. Batteries shall conform to the curvature of the above cited curved surface and maintain no greater than 3/16 inch distance between the curved surface and entire battery surface while conformed. When tested in accordance of 4.7.3.16 batteries shall meet the conformability capacity requirements of 3.5.3 and the requirements of 3.12 .

Add:

3.6.15 Chemical resistance.

Batteries shall not be affected by common chemicals in the operational environment such as military decontamination or fuel. When testing in accordance of 4.7.3.17 batteries shall meet the requirements of TABLE VIII.

3.7 Safety.

Add: Batteries shall be evaluated for any unsafe conditions when penetrated by a sharp object(s). An unsafe condition includes but not limited to, (a) temperature above 170 oC (338 oF) on the surface of the battery case, (b) sustained flame and/or smoke generation, (b) violent reaction or (d) ejection of materials that present an unsafe condition to the user when tested as specified in 4.7.4.12 and 4.7.4.13. The battery shall not exhibit any of the aforementioned unsafe conditions for not less than two minutes after the penetration of the last object as required by the specific test. The results of this test shall support a hazard no higher than a MEDIUM risk IAW MIL-STD-882.

3.7.1.2 Nail Penetration, Cell.

Replace MIL-PRF-32383 Section 3.7.1.2 Nail Penetration, Cell with the following:

3.7.1.2 Nail Penetration, Cell.

When specified (see 3.1), cells shall not react violently when cell containers are penetrated by sharp objects. Cells tested in accordance with 4.7.4.4 shall not burn or explode, and the external temperature of each test sample shall be not greater than 170°C (338ºF). The results of this test shall be evaluated and shall be not greater than a MEDIUM risk in accordance with MIL-STD-882.

Add:

3.7.2.2.1 Overvoltage protection.

The battery shall withstand not less than 50V continuous both on the Nett Warrior connector and charge terminal contacts.

3.7.2.4 High temperature temporary cutoff devices.

Add: The quantity of thermo-switches shall be not less than 2. Certification is required

3.7.2.6 Projectile.

Replace MIL-PRF-32383 Section 3.7.2.6 Projectile with the following:

3.7.2.6 Projectile.

When tested, the production of smoke and flames and the passing of small particles through the wire mesh are permitted; heat damage to the wire mesh is also permitted. Test must be set up in accordance to UL1642 20 Projectile Test. During test, batteries must be secured to the screen with a single wire tied around the sample. Video of the test is required from start of testing to end of testing for each battery. Pictures are to be taken and to include but are not limited to; pre-test apparatus (including all equipment), pre-test battery, post-test battery, post-test apparatus (including all equipment), post-test room, and any post-test shrapnel found with reference object. The results of this test shall be evaluated and shall be not greater than a MEDIUM risk in accordance with MIL-STD-882.

Add:

3.7.2.8 Safety, battery.

Add:

3.7.2.8.1 Nail penetration, battery.

When tested IAW 4.7.4.12, batteries shall be capable of safely withstanding penetration by sharp objects as called out in 3.7. Battery should continue to provide degraded operational capability after being punctured. However, if a cell in the battery is determined to have failed, charging shall be disabled and SOH should be reported as flashing “000.”

Add:

3.7.2.8.2 Protective devices.

The battery shall include protective devices/circuitry/material to prevent thermal event propagation between cells. Certification is required.

Add:

3.7.2.8.3 Weapons characterization.

Batteries shall be capable of safely withstanding penetration by bullets/projectiles and not have propagation to adjacent cells. Safety characterization tests shall be conducted in accordance with 4.7.4.13 and 4.7.4.13.1.

Add:

3.7.2.8.4 Battery safety protection circuits.

The battery shall include three (3) distinct and separate protective devices/circuitry/material to prevent improper charging, system overload, or system malfunction, disabling energy entry or exit as needed to prevent catastrophic outcomes. Batteries shall have a battery management system, no less than two FETS, a resettable and permanent fuse protecting all of the terminals, connections, and shielding. Certification required.

3.8 Electromagnetic compatibility.

Add: The battery shall be appropriately filtered and shielded to comply with the applicable emissions and susceptibility requirements of MIL-STD-461 Table V, Aircraft, Army, including Flight Line as specified in 4.7.7.

3.9 Transportation requirements.

Delete and replace with “Batteries shall be prepared for shipping IAW UN ST/SG/AC.10/11 current revision of 49 CFR Parts 171, 172, 173, 175 Hazardous Materials: Transportation of Lithium Batteries.”

3.10 Interchangeability.

Add: Applicable “currently fielded” chargers are listed under 4.6.3

Add:

3.11 Reliability

The battery shall have a reliability of at least 468 hours Mean Time Between Essential Function Failure (MTBEFF). A reliability Essential Function Failure is defined as any incident that results in the inability for the battery to perform its essential functions as specified in paragraph 3.5.2 (Battery voltage), 3.5.3 (Capacity), 3.4.4.1.5 (USB), 3.5.6 (Charge enable), 3.5.8 (Digital Display Characteristics), 3.5.9 (SMBus), 3.5.10 (Operating Temperature), 3.5.10.1 (Charge Acceptance), 3.5.11 (Concurrent Charge), 3.13 (System Integration), or creates a personal unsafety condition as specified in 3.7 (Safety). This requirement is based on a typical annual usage rate of 2585 hours. When tested as specified in 4.7.2.4.1 batteries shall meet the requirements of 3.11 and 3.12

Add:

3.12 Basic Functionality Test

When tested as specified in 4.7.9, the battery shall be capable of performing its system operational functionality.

Add:

3.13 Systems level Integration

The battery shall be capable of supplying voltage (volts) as defined in Section 3.5.2 to a connected to the intended integrated U.S. Army system(s), defined at contract award and depicted in Figure 13, IAW with current (amps) requirements in Section 3.5.5.

4. VERIFICATION

4.4 First article inspection.

Modify MIL-PRF-32383 battery sample sizes as defined below:

a. Group 1 (GR1) – Functional tests: increase sample size from 12 samples to 16 samples.

b. Group 2 (GR2) – Electromagnetic interference tests: decrease sample size from 5 samples to 2 samples.

Add:

e. Group 5 (GR5) – Nail penetration tests (battery level) and Weapons Characterization tests - sample size of 18

f. Group 6 (GR6) – Reliability verification tests – sample size of 3.

Replace Table IV with the following:

Table IV First Article Tests NOTE: Each group MUST be tested in the order listed in the table.

Test Method

Samples or Group (GR)

(2 ea)

GR3

(8 ea)

GR4

(15 ea)

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

C

G

C

(1) – Contractor(C) and/or Government (G) conducted test. Note, the Government at any time can choose to witness or verify compliance with any test.

4.5.1 Group A inspection.

Add: to TABLE V of MIL-PRF-32383 the following rows at the bottom of table:

4.5.2 Group B inspection.

Replace: Replace TABLE VI of MIL-PRF-32383 with the following (tests shall be performed in the order listed below):

Modify: Battery sample size defined as part of the contracted effort shall take precedence, and may be different than the quantities specified in 4.5.2. The minimum battery sample size in 4.5.2 shall be not less than 8 samples. Samples executed under percentages C and D above, if they pass the Capacity discharge (initial) 3.5.3, and are in new condition (Refer to requirements of 3.4), they may be provided as deliverable items unless specified otherwise by the contract.

4,5.3 Group C inspection.

Modify: Battery sample size defined as part of the contracted effort shall take precedence, and may be different than the quantities specified in 4.5.3. The minimum battery sample size in 4.5.3 shall be not less than 4 samples.

4.5.3.1 Group C frequency.

Replace: Replace TABLE VII of MIL-PRF-32383 with the following (tests shall be performed in the order listed below):

NOTE: 1/: For Basic Functionality Test 3.12 capacity verification, use 3.5.3 Capacity Retention of charge Minimum Capacity of 3.5.10.2 - based upon Capacity Discharge Test Method Paragraph 4.7.2.3.

4.6.1 Constant potential, current limited.

Add: A constant potential of 16.8 volts or appropriate voltage requested via the SMBus interface shall be applied with current up to 7.5 amperes, to a charge cut off of 750 milli-amperes.

4.6.3 Alternate charging.

Add: The battery shall be compatible with the below charger. The following chargers may be used whenever the requirement allows use of alternate charging:

4.7.1.3 Connector insertion test.

Add:

Mate and un-mate the connector with a plug having the 6-7 pin configuration. Perform a visual inspection on the plug and socket and verify no pins or sockets are crushed, recessed, or otherwise damaged. Batteries shall meet requirements in 3.4.4.1.1.

Add:

4.7.1.3.1 Nett Warrior connector disconnect pull force test.

a. Secure battery in a stationary holding device and grip the cable 6 to 12 inches away.

b. The grip should not slip or damage the cable during the test.

c. Apply a static force of between 16.1 and 16.5 pounds.

d. Verify that the quick disconnect breaks.

e. Perform a visual and mechanical examination in accordance with 4.7.1.1.

f. Repeat steps a-e with a force between 7.9 and 7.5 pounds and verify item does not disconnect.

Batteries shall meet requirements in 3.4.4.1.1.1.

4.7.1.4 Flat terminal strength.

Add:

a. Secure battery in a stationary holding device and apply a point force with a 20 Lbs. force for 10 minutes to the center of the right most flat terminal.

b. Repeat step a for the 2nd contact.

c. Repeat step a for the 3rd contact.

d. Repeat step a for the 4th contact.

e. Visually inspect contacts to see that there is no deformation or separation of housing.

f. Conduct an 1 meter immersion of the battery for two hours. Verify that there was no ingress of water into battery.

Batteries shall meet requirements in 3.4.4.1.2.

Add:

4.7.1.8 Surface friction.

Verify battery surface is dry and free of any lubricants prior to test. Measure and report the coefficient of static friction per test method D2394 of ASTM G115-10, Standard Guide for Measuring and Reporting Friction Coefficients. Verify that the value is not greater than 0.4. Batteries shall meet requirements in 3.4.5.6.

4.7.2.3 Capacity discharge.

Replace: a. with: “Charge batteries IAW 4.6. Use of 4.6.3 is acceptable.”

Add: to c. Use a constant rate of 18 W.

Add: Press and release digital display actuator. Observe display and verify operability.

4.7.2.4 Cycle life test.

Delete 4.7.2.4 from MIL-PRF-32383 in its entirety and replace with the following:

4.7.2.4 Cycle life test.

a. Cycles 1 through 27 - Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted. Allow batteries to rest for not greater than one hour. Discharge at 18 W to cutoff voltage. Allow batteries to rest for not greater than one hour prior to the start of the next cycle. Every seventh cycle a rest of not greater than five hours is permitted before and after charge.

b. Cycle 28 - Charge the batteries in accordance with 4.6; use of 4.6.3 is permitted. Perform the electric leakage test of 4.7.4.7d. Allow batteries to rest for not less than 4 hours. Discharge at 2A to cutoff voltage. Record battery capacity.

c. Repeat steps a through b above until the 125 cycles are obtained.

d. After completion of the cycle life test, visually examine batteries for the criteria of TABLE VIII. Batteries shall meet the cycle life and visual mechanical requirements (see 3.1 and 3.5.3)

Add:

4.7.2.4.1 Reliability Test

The following test shall be performed to verify the reliability MTBEFF requirement. A minimum of three (3) batteries shall be used. All batteries shall undergo cycles A, B, C, and D described herein and accrue a cumulative minimum of 760 hours of operation with zero reliability failure allowed. In addition, each battery sample shall complete Cycles A, B, C, and D sequentially and accrue a minimum of 250 hours each. Record the Battery Cycle Count for each battery prior to conducting this test.

Cycle A: Battery Operation at -10 degrees C (14 degrees F)

a. Set chamber temperature to not more than -10°C (14°F).

b. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

c. Allow batteries to rest for one hour.

d. Discharge at 18 W to cutoff voltage.

e. Allow batteries to rest for one hour.

f. Record elapsed time from step b to step e. Record cumulative hours.

g. Repeat Step b to Step f for 3 times.

h. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

i. Allow batteries to rest for one hour.

j. Discharge at 30 W to cutoff voltage.

k. Allow batteries to rest for one hour.

l. Record elapsed time from step h to step k. Record cumulative hours.

m. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

n. Allow batteries to rest for one hour.

o. Discharge at 40 W to cutoff voltage.

p. Allow batteries to rest for one hour.

q. Record elapsed time from step m to step p. Record cumulative hours of Cycle A.

Cycle B: Battery Operation at 22 degrees C (72 degrees F) (+/- 4°C)

a. Set chamber temperature to 22°C (72°F) (+/- 4°C).

b. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

c. Allow batteries to rest for one hour.

d. Discharge at 18 W to cutoff voltage.

e. Allow batteries to rest for one hour.

f. Record elapsed time from step b to step e. Record cumulative hours.

g. Repeat Step b to Step f for 10 times.

h. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

i. Allow batteries to rest for one hour.

j. Discharge at 30 W to cutoff voltage.

k. Allow batteries to rest for one hour.

l. Record elapsed time from step h to step k. Record cumulative hours.

m. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

n. Allow batteries to rest for one hour.

o. Discharge at 40 W to cutoff voltage.

p. Allow batteries to rest for one hour.

q. Record elapsed time from step m to step p. Record cumulative hours of Cycle B.

Cycle C: Battery Operation at 40 degrees C (104 degrees F)

a. Set chamber temperature to not less than 40°C (104°F).

b. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

c. Allow batteries to rest for one hour.

d. Discharge at 18 W to cutoff voltage.

e. Allow batteries to rest for one hour.

f. Record elapsed time from step b to step e. Record cumulative hours.

g. Repeat Step b to Step f for 3 times.

h. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

i. Allow batteries to rest for one hour.

j. Discharge at 30 W to cutoff voltage.

k. Allow batteries to rest for one hour.

l. Record elapsed time from step h to step k. Record cumulative hours.

m. Charge batteries in accordance with 4.6; use of 4.6.3 is permitted.

n. Allow batteries to rest for one hour.

o. Discharge at 40 W to cutoff voltage.

p. Allow batteries to rest for one hour.

q. Record elapsed time from step m to step p. Record cumulative hours of Cycle C.

Cycle D: Conduct Battery Essential Function Tests.

a. Charge batteries in accordance to with 4.6; use of 4.6.3 is permitted.

b. Perform the electric leakage test of 4.7.4.7d

c. Allow batteries to rest for not less 4 hours.

d. Discharge at 2A to cut off voltage.

e. Record Battery capacity.

f. Record elapsed time from step b to step e.

g. Record cumulative hours of Cycle D.

After completion each Cycle A, B, C, and D test, visually examine batteries for the criteria of 4.7.1.1 TABLE VIII. Record the Battery Cycle Count for each battery after above testing.

The total cumulative hours of each battery shall be the cumulative hours of cycles A through D. Verify that the cumulative hours meet or exceed the requirements of 3.11.

Verify that the battery operates and passes the basic system functionality requirements of 3.12.

4.7.2.9 Charge acceptance.

Modify MIL-PRF-32383 as defined below:

- Change Step C to “Charge batteries with a Smart Battery Specification compliant charger.”

- Change the temperature in Step F from 50°C to 55°C.

4.7.2.11 Pulse discharge.

Add: Discharge at 5 A for 5 seconds, rest for 25 seconds. Continue discharge to final voltage

4.7.2.14 State-of-charge indicator.

Delete 4.7.2.14 from MIL-PRF-32383 in its entirety and replace with the following:

4.7.2.14 Digital display characteristics.

The following test shall be performed. Verify that measurements and details are in accordance with the requirements of 3.5.8.

a. Charge each battery in accordance with 4.6; use of 4.6.3 is permitted.

b. Verify location and marking of the digital display indicator is in accordance with 3.5.8.

c. Press and release the digital display actuator.

d. Measure and record the following to the nearest tenth of a second: (1) time from actuation to full intensity of the lights or digital display; (2) time from reaching full intensity until the lights extinguish; and (3) the total time from actuation until the…